Chevron Specification PIM-EG-3541-B

FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

SPECIFICATION PIM-EG-3541-B
FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

October 1997 Page 1 of 9

Chevron Specification PIM-EG-3541-B
FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

CONTENTS
1.0 SCOPE ...................................................................................................................................................3

2.0 TESTING FLUID .................................................................................................................................3

3.0 FIELD PROCEDURE .........................................................................................................................3

3.1 Joint Visibility.........................................................................................................................................3
3.2 Isolation for Test.....................................................................................................................................3
3.3 Equipment Preparation ...........................................................................................................................4
3.4 Pressure Gages........................................................................................................................................5
3.5 Relief Valves...........................................................................................................................................5
3.6 Venting and Filling.................................................................................................................................5
3.7 Hydrotest Pressure ..................................................................................................................................5
3.8 Inspection During Test ...........................................................................................................................6
3.9 Freeze Protection ....................................................................................................................................6
3.10 Defects ....................................................................................................................................................6
3.11 Precautions on Hydrotesting Heat Exchangers......................................................................................6
3.12 Draining Test Fluids ...............................................................................................................................7
4.0 SAFETY CONSIDERATIONS DURING TESTING......................................................................7

5.0 TEST REPORTS AND CERTIFICATIONS ...................................................................................8

6.0 ATTACHMENTS.................................................................................................................................9

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Chevron Specification PIM-EG-3541-B
FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

1.0 SCOPE

1.1 This specification outlines general requirements for pressure testing of piping systems and
connected equipment to assure mechanical strength and tightness in accordance with applicable
ANSI/ASME codes. The Field Hydrotest Schedule and associated diagrams give detailed
testing requirements and procedures.

1.2 This specification does not apply to service testing of low-pressure utility lines (air, water, and
steam not exceeding 150 psig) nor to pneumatic testing.

1.3 This specification does not apply to equipment, including packaged assemblies, previously
tested by the manufacturer in accordance with Company requirements and applicable Codes.

1.4 This specification does not apply to atmospheric sewers and drains nor to plumbing systems for
buildings.

2.0 TESTING FLUID

2.1 The normal test fluid is clean, potable-quality fresh water. Test water used for chrome-nickel
300 Series stainless steel piping shall have a chloride content less than 100 ppm.

2.2 If any fluid other than clean fresh water is to be used for pressure testing, it will be specified in
the Field Hydrostatic Test Schedule or must have written Company approval.

2.3 The test fluid temperature shall be between 40°F and 120°F unless specifically approved by the
Company. Temperature shall be not less than the minimum pressurizing temperature (MPT)
stated on the Field Hydrostatic Test Schedule. Metal temperatures of piping and equipment
must not fall below the minimum pressurizing temperatures.

3.0 FIELD PROCEDURE

3.1 Joint Visibility

All welds and joints not previously tested shall be left unpainted, uncoated, uninsulated and
exposed for inspection during the test. Underground lines shall be tested before wrapping the
joints, placing in a sleeve, or backfilling.

3.2 Isolation for Test

3.2.1 Disconnect or blind off from the piping and equipment being tested all pressure gages,
meters, gage glasses, relief valves, or other equipment not capable of withstanding the
test pressure, and all service lines and equipment not included in the test.

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Chevron Specification PIM-EG-3541-B
FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

3.2.2 Valves may be used to isolate equipment and sections of piping having different test
pressures, provided they are suitable for the test pressure; valve discs and seats may be
distorted if they are closed against a system test pressure that exceeds the allowable
seat test pressure. Check that the system test pressure does not exceed the valve-seat
test pressure. Generally valve-seat test pressure is 110% of valve design pressure.
Valve seating may not be "bubble-tight" against test pressure; precautions shall be
taken so that any valve leakage does not overpressure the system on the other side of
the valve.

3.2.3 Where valves are closed in lieu of blinding, the line or vessel on the low pressure side
of the valves must be vented or protected with a relief valve. Valve leakage makes it
difficult to hold pressure during the test and requires extreme care in looking for leaks,
because one cannot rely on holding pressure as a check of tightness. If leakage is a
problem, blind at the low pressure side of the valve and open the valve.

3.2.4 Body-relief valves on valves such as double-block-and-bleed and similar types may
weep or discharge at test pressures and thus may need to be removed or plugged for the
test.

3.2.5 Where a welded valve separates two sections of piping with different hydrotest
pressures and the pressures are such that the higher test pressure exceeds the maximum
allowable valve seat pressure, both sections shall first be tested at the lower pressure,
with the valve in question open. The valve shall then be closed and the hydrotest
pressure raised to that required on the high pressure side of the valve, while
maintaining sufficient pressure on the lower side to keep the differential from
exceeding the maximum allowable seat pressure. When this procedure is required,
each piping section must be protected from overpressure by a test relief valve.

3.2.6 If mechanical plugs (such as Thaxton plugs) that fit inside the pipe are used to close
ends of pipe, their locations shall be clearly marked. Particular care must be taken to
ensure that they are removed at the end of the test. The Company Inspector shall
witness installation and removal of mechanical plugs.

3.2.7 Factory stops on expansion joints and spring supports shall remain in place during
testing and flushing.

3.2.8 Temporary gaskets may be used at connections that will be blinded for testing and
reassembled after testing.

3.3 Equipment Preparation

3.3.1 Remove in-line and direct-connected instruments (e.g., orifice plates, displacement
meters, rotameters, turbine meters, displacers, etc.) and reinstall after testing and
flushing.

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Chevron Specification PIM-EG-3541-B
FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

3.3.2 Control valves may be tested with the piping unless specifically exempted. Valves
shall be in the open position and the packing evenly tightened before testing.

3.3.3 Ball valves and through-conduit gate valves shall be partially opened to equalize
pressure between the trim and body cavity.

3.4 Pressure Gages

Install an indicating pressure gage on the test pump discharge piping so that it is visible to the
pump operator, who shall stand by the pump throughout pressuring of the system. Use only
recently calibrated pressure gages for test purposes. Use a gage with a range that registers the
test pressure between 50 and 80% of gage scale. If the major equipment is located beyond easy
sight of the pressure gage at the pump, install a second calibrated test gage near the equipment.

3.5 Relief Valves

Install a properly sized relief valve on the test pump discharge (no relief valve is required on
hand test pumps). Set the relief valve at approximately 105% of the hydrostatic test pressure at
the elevation of the relief valve (adjusting for hydrostatic head). The size of the valve shall be
sufficient to discharge the maximum capacity of the pump at the test pressure. Any valves
between the relief valve and the system being tested shall be locked open.

3.6 Venting and Filling

3.6.1 Vent high points in the system so that air will be displaced from the system while it is
being filled with the test fluid. Vents shall be readily accessible.

3.6.2 When preparations have been completed, the system may be filled with the test fluid.
When air has been properly bled from the system, close the vents.

3.7 Hydrotest Pressure

The hydrotest pressure shall be applied slowly and maintained at test pressure for as long as is
necessary to make a complete inspection of the system under test, but in no case for less than
the minimum duration required by the applicable Code. These minimums are:
ANSI/ASME Code Minimum Time at Test Pressure
B31.1 10 minutes, after which the pressure may be reduced to design
pressure (two-thirds test pressure) while completing the
inspection
B31.3 10 minutes
B31.4 4 hours (plus an additional four hours if the piping cannot be
visually inspected)
B31.8 2 hours
Due care shall be exercised during the test period to avoid overpressure or vacuum damage due
to temperature change and resulting test fluid volume change.

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Chevron Specification PIM-EG-3541-B
FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

3.8 Inspection During Test

3.8.1 While the system is under test pressure, the Contractor and the Company Inspector
shall make a close inspection of the piping system for sweats, cracks, or other defects,
paying special attention to castings (particularly at fillets and at sudden changes in
section), forgings, and repairs to existing equipment. Defects or suspected defects shall
be marked with suitable crayon or paint to aid in locating for repair.

3.8.2 Keep personnel away from pressure vessels while the test pressure is applied. The
pressure shall then be dropped to the maximum allowable working pressure before
anyone is allowed on the vessel for a close inspection. If there should be any leakage at
vessel welds, the system shall be depressured, repairs made, and a retest conducted.

3.8.3 In rainy weather, it is difficult to see leaking water. To check for leaks in rainy
weather, pressure the system to test pressure and hold for at least 1 hour. If there is a
pressure loss, further inspection shall be made.

3.9 Freeze Protection

Special precautions shall be taken in freezing weather (especially with equipment that is likely
to freeze such as air coolers). Special care shall be taken to drain the system completely after
testing is completed.

3.10 Defects

3.10.1 If there is any indication of yielding or incipient failure of equipment or supports at any
time while building up the pressure, stop pressuring, carefully reduce the pressure,
drain if necessary, and report the situation to the Construction Manager for further
instructions.

3.10.2 The Company Inspector shall report all defects to the Construction Engineer and shall
follow the necessary repairs made by the Contractor. The test shall be repeated after
repairs. Serious defects shall be reported to the Construction Manager for decision as
to the method of repair.

3.11 Precautions on Hydrotesting Heat Exchangers

When hydrotesting heat exchangers that have a tube sheet designed for differential pressures
less than either the shell or tube side design pressure, special steps shall be taken to avoid
overstressing the tube sheet. Pressure shall be applied to both shell and tube sides
simultaneously to avoid exceeding this differential. If a large hydrotest system is depressurized
rapidly, one side of the exchanger may lose pressure much more rapidly than the other. The
momentary differential pressure can then exceed the allowable differential pressure, causing the
tube sheet to fail. Caution must be exercised as follows:

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Chevron Specification PIM-EG-3541-B
FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

• Install both a pressure gage on the shell side and a pressure gage on the tube side. Monitor
the pressures on each side of the exchanger simultaneously throughout the test.

• Release both pressures slowly as follows: Release the pressure in incremental amounts
(lesser of 50 psi or 10%). After each increment, allow the system to reach equilibrium
before continuing.

• Drain and vent after the system reaches atmospheric pressure.

3.12 Draining Test Fluids

3.12.1 At the completion of a test and inspection, the Company Inspector shall check that the
top of each vessel to be drained is vented to the air before drainage begins, and that it is
drained slowly so that a vacuum will not be formed. The Inspector shall also be sure
that the hydrotest relief valve is not removed until draining is substantially complete
and that no part of the system is blocked in and not drained promptly after testing. This
ensures that the test fluid is not left in the system and subject to thermal expansion.
Drain piping and equipment promptly, dry as specified in the Field Hydrostatic Test
Schedule, and otherwise protect against corrosion until it can be placed in service.

3.12.2 Drain at low points in such a manner as to effectively wash out loose materials.
Mechanical plugs in the piping must be removed promptly; be sure the line is
depressured and drained before loosening the plug. The test fluid may be saved and
transferred for use in other system tests. The entire system must be fully depressurized
and vented before leaving the job.

4.0 SAFETY CONSIDERATIONS DURING TESTING

A large amount of energy is stored in a closed system under test. A sudden release of this energy due
to failure can be disastrous. For this reason, the Contractor shall take all reasonable safety
precautions. These include the following:

4.1 When filling a system, have all vents open and thoroughly vent air to minimize air trapped in
the system.

4.2 See that the person assigned to operate the test pump remains at the pump at all times during the
test to observe pressure or bleed overpressure in an emergency.

4.3 See that a relief valve that is set at 105% of the test pressure and is of adequate capacity is
installed on the pump discharge. If the system under test is pressured directly from plant
process water or from the utility water system, install a relief valve that is set at 105% of the
test pressure and is of adequate capacity close to the tie-in connection of the system under test.

4.4 See that the calibrated indicating pressure gage(s) are connected at the test pump discharge and
near major pressure vessels.

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Chevron Specification PIM-EG-3541-B
FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

4.5 See that all appurtenant equipment used in the test is safe for the test pressure. This includes
such components as expansion joints, swivel connections, gages, test pump appurtenances, and
the lines or hose between the pump or pressure source and the equipment.

4.6 Verify that all structural supports of large gas or vacuum lines can withstand the weight of a
liquid-filled line. Provide additional supports, if necessary, to support the weight of the test
fluid.

4.7 Be sure that the full number of properly tightened bolts of the right size and material are used in
all bolted joints. Because the test pressure is greater than the service pressure, any reduction in
the number, size, or quality of the bolts may cause them to be overstressed and fail.

4.8 Verify that the proper test fluid is used and that the temperature is above the minimum
pressurizing temperature shown on the Field Hydrostatic Test Schedule. Take adequate safety
precautions if hot water or steam is used for heating.

4.9 Verify that the supply for fill and pressuring is on the upstream side of any check valve in the
system. After the test, see that piping on both sides of check valves is vented and drained.

4.10 Keep personnel away from pressure vessels while the test pressure is applied.

4.11 Take the following extra precautions when making high pressure tests or tests where a large
amount of liquid is involved (i.e., spheres, large vessels, long large lines, etc.).

• Keep everyone not essential to the test away from the test area.

• See that the test pump is located so that the pump operator is in a safe area.

• Stop the pump at about half the test pressure and inspect for leaks and other signs of
weakness. After the preliminary inspections, stay in the clear until the full pressure is
reached. Drop the pressure to design pressure before making a close inspection.

5.0 TEST REPORTS AND CERTIFICATIONS

5.1 Test report data shall include:

• System tested, line numbers, equipment numbers

• Date and time

• Design pressure and temperature

• Test fluid (and chloride content, if testing Series 300 austenitic stainless steel)

• Test fluid temperature

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Chevron Specification PIM-EG-3541-B
FIELD HYDROSTATIC TESTING OF PIPING SYSTEMS

• Test pressure

• Pressure chart

• Relief valve set pressure and capacity

• Calibration data for pressure gages and recorders

• Ambient temperature

• Time test pressure reached, time depressuring started

• Pressure recorder serial number, range, and chart range

• Remarks regarding leakage and defects

• Name of Contractor Superintendent responsible for testing

• Name of Company Inspector or Engineer witnessing the test

5.2 After a successful test, the Company Inspector shall certify that the system has satisfactorily
passed pressure testing in accordance with the particular Code.

5.3 Certification by a Code-certified inspector is required if testing applies to steam-generating

equipment, air tanks, or other ASME Code equipment fabricated or altered in the field.

6.0 ATTACHMENTS

The following is a part of this specification:

Field Hydrostatic Test Schedule, with associated diagrams

October 1997 Page 9 of 9